Abstract: A continuous and flexible method and apparatus is provided for applying one or more coating materials to internal and/or external portions of a fiber batt to provide edge and surface coating layers on those surfaces of the fiber batt that will be exposed during subsequent use. The invention provides for the coating to be applied selectively all exposed surfaces of a fiber batt and provided internally within the fiber batt for later splitting into opposing edges, thereby improving both the manufacturing process and the consistency and flexibility of the resulting product by reducing or eliminating the need for subsequent manual coating of unfinished edge surfaces.

Abstract: A compatibilized polyolefin/polyolefin composite material includes a polyolefin/polyolefin composite substrate and a reinforcing mat formed from reinforcing fibers and a thermoplastic polymer powder. The mat may also incorporate an optional emulsion polymer binder. In addition the compatibilized polyolefin/polyolefin composite material may incorporate an additional film layer so that the mat is sandwiched between the substrate and the film layer. A method of producing such materials from a polyolefin/polyolefin composite substrate that is topologically/mechanically bonded to a reinforcing mat formed from reinforcing fibers and thermoplastic polymer powder is also described.

Abstract: A method for making moldable material comprises the initial step of providing a composite material comprised in part of an epoxy. A high performance strand is then distributed in the composite material to form a moldable material. Lastly, the moldable material is heated sufficiently to cause the composite material and the high performance strand to stick at least slightly together without melting the epoxy.

Abstract: A moldable pellet used for making high impact, non-abrasive recyclable structural composites consisting of a thermoplastic polymer or polymers, with or without fillers and additives, and a synthetic cellulosic fiber in yarn or tow form such as Rayon or Lyocell. The concentration of cellulose fiber within the pellet may vary from approximately 2-80 percent by weight or higher. This moldable pellet is suitable for molding in current molding applications such as, but not limited to, injection molding, extrusion compression molding, and compression molding.

Abstract: A construction beam includes a pair of lateral members and a resilient web extending therebetween, so as to present a cross-sectional profile corresponding to commonly used construction beam members. The resilience of the web helps to attenuate sound transmission through the beam from one lateral member to the other. Ends of the resilient web are fixed to respective ones of the lateral members on opposite sides of an imaginary reference plane passing orthogonally through both of the lateral members. In particular, in a wall frame, the lateral members are mounted at opposite ends thereof to end plates consisting of other construction beams according to the present invention. When used in a frame of a building structure, the lateral members of the end plates on the same side are attached to the surrounding structure, leaving the other side of the frame resiliently free floating.

Abstract: An acoustical liner with integral water barrier is provided. The liner includes a pad of fibrous material having a lofty, acoustically insulating portion and at least one heat-seared face of relatively higher density to provide water barrier protection. The acoustical liner is a non-laminate made from polyester, fiberglass, polypropylene and any mixtures thereof. A method of insulating a door including an exterior body panel and an interior fascia panel as well as a door for a vehicle are also disclosed and claimed.

Abstract: A method of co-texturizing glass fibers and thermoplastic fibers comprises passing a glass fiber strand through a texturizing gun, simultaneously passing a thermoplastic fiber strand through the texturizing gun with the glass fiber strand and injecting pressurized air into the texturizing gun concurrently with the glass fiber strand and thermoplastic fiber strands. This method produces a co-texturized fiber material comprising between 20-85% by weight glass fiber and 15-80% by weight thermoplastic fiber having an overall density of from about 20 grams/liter to about 200 grams/liter, and preferably from about 20 grams/liter to less than about 30 grams/liter.

Abstract: A structurally enhanced, insulating sheathing (10) and method of sheathing a frame of the type used in constructing a building are disclosed. In one embodiment, the sheathing includes an insulating layer of material (14) attached to a structural layer of material (12) formed of a plurality of fibers (12al-12an), preferably biased in first and second directions (D1, D2) relative to a common axis, such as the longest centerline of the sheathing. The fibers form a grid (12c) having a plurality of openings (12d) that are capable of receiving an adhesive (A3) for attaching the sheathing to a stable mounting structure, such as a frame. Preferably, the adhesive is capable of penetrating at least partially into the openings to ensure that a secure, lasting bond is formed. In a second embodiment the sheathing includes a multilayer polymer film with a low melting point adhesive thereon.

Abstract: A construction beam includes a pair of lateral members and a resilient web extending therebetween, so as to present a cross-sectional profile corresponding to commonly used construction beam members (e.g., 2″×4″ or 2″×6″). The resilience of the web helps to attenuate sound transmission through the beam from one lateral member to the other. In particular, in a wall frame, the lateral members are mounted at opposite ends thereof to end plates consisting of other construction beams according to the present invention (i.e., a pair of lateral members with resilient web extending therebetween).

Abstract: The presently disclosed invention relates to a phenolic binder comprising a premix of a urea modified phenol-formaldehyde resole resin, a curing agent, and an additive selected from the group consisting of ammonium lignosulfonate, melamine and a melamine derivative. A method for reducing gaseous emissions in the manufacture of fibrous insulation materials is also disclosed.

Abstract: A screen comprises an electrically conductive elongate inner screen plate. The inner screen plate has at least one elongate fold therein and at least two elongate divergent surfaces on opposing sides of the fold. Each divergent surface has an upper end and opposing edges tapering downward from the upper end. The upper ends of the divergent surfaces diverge from one another. Each of the divergent surfaces has a plurality of holes therein. The screen further comprises at least two electrically conductive outer screen plates. The outer screen plates are attached to the edges of the divergent surfaces and extend between the divergent surfaces. Each of the outer screen plates has a plurality of holes therein. Another embodiment of the invention is directed toward a glass fiber bushing system comprising a bushing body and a screen within the bushing body. The bushing body has opposing end plates. The screen comprises opposing ends. Each of the ends has an upper portion and a lower portion.

Abstract: A formaldehyde free co-binder solution formed by using a polyol to crosslink polycarboxylic acid and a polyacid monomer is provided. In forming the co-binder solution, the polyacid monomer and the polyol are mixed in any conventional device with heat and agitation for a period of time sufficient for the chemicals to react and form a reaction product. The resultant product is then admixed with polycarboxylic acid to form a co-binder solution. In a preferred embodiment, the polyacid is maleic anhydride and the polyol is triethanolamine.

Abstract: A drainage mat and mortar blocker system including a panel and polymeric drainage mat which includes protrusions on the front side and indentations on the back side of the mat. A filter fabric is affixed to the side of the mat containing the protrusions. The top portion of the back side of the drainage mat is affixed to the panel and the bottom portion of the mat is folded upward so as to form a U-shape. The U-shape is held in place by connections extending from the back side of the bottom portion of the drainage mat and into the front side of the drainage mat.

Abstract: A liner/insulator includes a pad of fibrous material having a lofty, acoustically insulating portion and a relatively higher density skin along a first face thereof that may function as a water barrier. The acoustical liner is a non-laminate made from polyester, polyethylene, polypropylene, polyethylene terephthalate, glass fibers, natural fibers and any mixtures thereof. For certain applications the liner/insulator may incorporate a facing on one or even two opposing faces thereof. A method of insulating a door including an exterior body panel and an interior fascia panel as well as a door for a vehicle are also provided.

Abstract: Apparatus for unloading a load from a container having a floor, includes a floor sheet placed on the floor of the container, the floor sheet having a top surface with a coefficient of static friction less than about 0.3. A pull sheet placed on the top surface of the floor sheet, the pull sheet having a bottom surface with a coefficient of static friction less than about 0.5. The pull sheet has a tensile strength sufficient to enable the pull sheet to be pulled from the container while maintaining the load on the top surface of the pull sheet to unload the load from the container.

Abstract: A process and apparatus for making densified glass fiber pellets substantially encapsulated in a polymeric shell from chopped segments of multi-filament glass strand is described. The densified pellets may be advantageously produced by hydrating chopped glass strands and then pelletizing them by tumbling in a rotary drum, densifying the resulting pellets by tumbling in a rotating zig-zag or undulating tube, drying the pellets and encapsulating them in a polymeric composition. The resulting pellets exhibit enhanced degradation resistance during bulk storage and handling.

Abstract: A construction beam includes a pair of lateral members and a resilient web extending therebetween, so as to present a cross-sectional profile corresponding to commonly used construction beams (e.g., 2″×4″ or 2″×6″). The resilience of the web helps to attenuate sound transmission through the beam from one lateral member to the other. In particular, in a wall frame, the lateral members are mounted at opposite ends thereof to end plates consisting of other construction beams according to the present invention. When the wall frame is used in a building structure, the lateral members of the end plates on the same side are attached to the surrounding structure, leaving the other side of the frame resiliently free floating. A wall is mounted on the free floating side of the wall frame so as to provide a resiliently free floating wall that acts as a sound attenuating absorber.

Abstract: The present invention generally relates to processes for preparing extruded foam products and more particularly to a process for producing such products wherein surface defects are minimized. There has been a movement to replace conventional halo-carbon blowing agents in favor of purportedly more environmentally safe halo-carbon free blowing agents such as carbon dioxide, nitrogen, argon, water, air, nitrogen, and helium. However, these halo-carbon free blowing agents, in particular carbon dioxide, have higher foaming rates and higher volatility leading to greater surface defects in the extruded foam. The present invention employs polyethylene wax to reduce or eliminate the occurrence of surface defects where halo-carbon free blowing agents are employed in an extruded foam manufacture process.

Abstract: A method for splicing fibrous mats including separating an edge of one fibrous mat into two sections, inserting an adhesive-containing edge of another fibrous mat between the two sections and applying heat to the adhesive-containing edge. Upon cooling, both of the mats are bonded together, forming a seam, completing the splice.

Abstract: A resiliently flexible construction beam includes a pair of lateral flange portions and a web extending therebetween, preferably, but not necessarily, so as to present a cross-sectional profile corresponding to commonly used construction beam members (e.g., 2″×4″ or 2″×6″). The resilience of the beam helps to attenuate sound transmission through the beam from one lateral member to the other. In particular, in a wall frame, beams according to the present invention are mounted at opposite ends thereof to end plates. In one example, the end plates include slits into which the webs of the beams can be received. The resilient web according to the present invention is conveniently made from a unitary piece of material such as, for example, steel.